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Abstract:

Embodiments of the invention provide an electric machine module including
an electric machine positioned with a housing. The brushless electric
machine includes a center axis of rotation and a support member coupled
to the housing. The module also includes a cooling system, which includes
an inlet disposed through a portion of the housing, a first channel
positioned within the support member that fluidly connects a second
channel with the inlet. The housing also includes a drain aperture and a
drain guide disposed substantially adjacent to the drain aperture.

Claims:

1. An electric machine module comprising: a housing including a sleeve
member coupled to at least one end cap, the housing defining a machine
cavity; an electric machine positioned within the machine cavity and at
least partially enclosed by the housing, the electric machine comprising
a brushless configuration, a central axis of rotation, at least one
recess, and a stationary support member coupled to a wall of the housing
and extending into the machine cavity; a cooling system at least
partially positioned within portions of the housing and support member,
the cooling system including a first inlet disposed through a portion of
the housing, a first channel at least partially disposed within the
support member and oriented substantially parallel to the central axis of
rotation, the first channel being in fluid communication with the at
least one inlet, and at least one second channel disposed within the
support member and oriented substantially perpendicular to the central
axis of rotation, the at least one second channel being in fluid
communication with the first channel and the machine cavity; and a drain
aperture disposed through at least a portion of the housing, the drain
aperture in fluid communication with the machine cavity; and wherein the
housing comprises at least one drain guide substantially immediately
adjacent to the drain aperture and adjacent to the at least one recess.

3. The electric machine module of claim 1, wherein the housing comprises
a first machine cavity and a second machine cavity.

4. The electric machine module of claim 3, wherein the first inlet and
the first channel are in fluid communication with at least the second
machine cavity.

5. The electric machine module of claim 3, wherein a rectifier assembly
is electrically connected to the stator assembly and at least partially
positioned within the second machine cavity.

6. The electric machine module of claim 1, wherein the cooling system
comprises a plurality of second channels.

7. The electric machine module of claim 1 and further comprising a third
channel coupled to a portion of the housing and a second inlet disposed
through a portion of the housing, and wherein the third channel fluidly
couples the first inlet and the second inlet.

8. The electric machine module of claim 7, wherein the housing comprises
a sleeve member coupled to a first end cap and a second end cap, and
wherein the first inlet is disposed through a portion of the first end
cap and the second inlet is disposed through a portion of the second end
cap.

9. The electric machine module of claim 1, wherein the electric machine
comprises a stator assembly substantially circumscribing at least a
portion of a rotor assembly, and wherein the stator assembly includes a
plurality of scallops and the at least one recess.

10. The electric machine module of claim 9, wherein the electric machine
is disposed within the housing so that the at least one recess is
disposed substantially immediately radially inward from the at least one
drain guide.

11. An electric machine module comprising: a housing defining a first
machine cavity and a second machine cavity, the housing including at
least one drain aperture and at least one drain guide; an electric
machine positioned within the first machine cavity and at least partially
enclosed by the housing, the electric machine comprising a brushless
configuration, a central axis of rotation, and a stationary support
member coupled to a wall of the housing and extending into the first
machine cavity, a field coil wound around at least a portion of the
stationary support member, a rotor assembly substantially circumscribing
at least a portion of the support member and the field coil, the rotor
assembly including two Lundell-type segments coupled together, and a
stator assembly including an insertion end, a weld end, and a stator core
comprising a plurality of axially oriented slots and a plurality of
scallops disposed around a substantial portion of an outer diameter of
the stator core and at least one recess, and wherein the electric machine
is positioned within the first machine cavity so that the at least one
recess is substantially radially inward from the at least one drain
guide, a stator winding at least partially positioned within the
plurality of slots, the stator winding including a distributed winding
configuration and comprising a plurality of conductors positioned in the
slots, each of the conductors including a turn portion extending between
at least two leg portions, the two leg portions including angled portions
and connection portions, wherein at least some of the turn portions of
the plurality conductors are positioned on the insertion side and at
least some of the angled portions and connection portions are positioned
on the weld side; and a cooling system at least partially positioned
within portions of the housing and support member.

13. The electric machine module of claim 11, wherein the cooling system
comprises a first inlet disposed through a portion of the housing; a
first channel at least partially disposed within the support member and
oriented substantially parallel to the central axis of rotation, the
first channel being in fluid communication with the at least one inlet;
and at least one second channel disposed within the support member and
oriented substantially perpendicular to the central axis of rotation, the
at least one second channel being in fluid communication with the first
channel and the first machine cavity.

14. The electric machine module of claim 13, and further comprising a
third channel fluidly connected to the first inlet and being in fluid
communication with the first machine cavity.

15. The electric machine module of claim 11, wherein the cooling system
comprises a plurality of second channels.

16. The electric machine module of claim 11, wherein the housing
comprises a sleeve member coupled to a first end cap and a second end
cap; and wherein the sleeve member comprises the at least one drain
aperture and the at least one guide.

17. The electric machine module of claim 11, wherein a region of the
stator core comprises a substantially recessed outer diameter, and
wherein the stator core is positioned within the housing so that the
region comprising a substantially recessed outer diameter is
substantially adjacent to the at least one drain aperture.

19. A method for assembling an electric machine module, the method
comprising: providing a housing defining a machine cavity, the housing
includes a sleeve member coupled to a first end cap and a second end cap;
positioning an electric machine within the machine cavity so that the
electric machine is at least partially enclosed by the housing, the
electric machine comprising a brushless configuration, a central axis of
rotation, a plurality of scallops, and at least one recess; coupling a
stationary support member to a wall of the housing and so that the
support member extends into the machine cavity; disposing a first inlet
through a portion of the first end cap; disposing a second inlet through
a portion of the second end cap; positioning a first channel within the
support member and oriented substantially parallel to the central axis of
rotation so that the first channel is in fluid communication with the
first inlet; disposing at least one second channel within the support
member and oriented substantially perpendicular to the central axis of
rotation, the at least one second channel is in fluid communication with
the first channel and the machine cavity; coupling at least one third
channel to a portion of the housing so that the third channel fluidly
connects the first inlet and the second inlet; disposing at least one
drain guide along an inner wall of the sleeve member so that the at least
one drain guide is immediately radially adjacent to the at least one
recess; and positioning at least one drain aperture thorough a portion of
the sleeve member so that the at least one drain aperture is
substantially immediately adjacent to the at least one drain guide.

20. The method of claim 19, wherein the inner wall of the sleeve member
comprises three drain guides.

Description:

BACKGROUND

[0001] Some electric machines, such as alternators and other generators,
are capable of generating an electric current, which can at least
partially re-charge a battery and/or provide current to other
electricity-requiring loads. Many of these electric machines produce
quantities of electricity that are generally commensurate with the
requirements of the structure into which the machines are installed. Some
of these electric machines include a rotating rotor assembly at least
partially positioned within a stator assembly. Some of these machines may
require a brushed configuration because of the rotating machine
components, which can impact power densities.

SUMMARY

[0002] Some embodiments of the invention provide an electric machine
module including a housing. In some embodiments, the housing can include
a sleeve member coupled to at least one end cap. In some embodiments, at
least some portions of the housing can define a machine cavity. In some
embodiments, an electric machine can be positioned within the machine
cavity and at least partially enclosed by the housing. In some
embodiments, the electric machine can comprise a brushless configuration
and a central axis of rotation. In some embodiments, the machine can
include a stationary support member coupled to a wall of the housing.

[0003] In some embodiments, the module can include a cooling system. The
cooling system can include at least one inlet disposed through a portion
of the housing and a first channel at least partially disposed within the
support member and oriented substantially parallel to the central axis of
rotation. In some embodiments, the first channel can be in fluid
communication with the at least one inlet. In some embodiments, the
cooling system can include at least one second channel disposed within
the support member and oriented substantially perpendicular to the
central axis of rotation. In some embodiments, the at least one second
channel can be in fluid communication with the first channel and the
machine cavity. In some embodiments, the housing can include at least one
drain aperture. In some embodiments, the drain aperture can be disposed
through a portion of the housing. In some embodiments, the housing can
comprise at least one drain guide substantially immediately

DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 is a cross-sectional view of an electric machine module
according to one embodiment of the invention.

[0005]FIG. 2 is a cross-sectional view of an electric machine module
according to one embodiment of the invention.

[0006] FIG. 3 is a partial view of a portion of a rotor assembly according
to one embodiment of the invention.

[0007]FIG. 4 is a perspective view of a support member according to one
embodiment of the invention.

[0008]FIG. 5 is a perspective view of a stator assembly according to one
embodiment of the invention.

[0009]FIG. 6A is a top view of a stator assembly according to one
embodiment of the invention.

[0011]FIG. 7 is a partial view of a stator lamination according to one
embodiment of the invention.

[0012]FIG. 8 is a perspective view of a conductor according to one
embodiment of the invention.

[0013]FIG. 9A is a side view of an electric machine module according to
one embodiment of the invention.

[0014] FIG. 9B is a side view of a partial cross section of an electric
machine module according to one embodiment of the invention.

[0015] FIG. 10A is a rear view of an electric machine module according to
one embodiment of the invention.

[0016] FIG. 10B is a cross-sectional view of a portion of the module of
FIG. 10A along line A-A.

[0017] FIG. 11A is a perspective view of a portion of an inner wall of a
sleeve member according to one embodiment of the invention.

[0018] FIG. 11B is a perspective view of a sleeve member according to one
embodiments of the invention.

[0019]FIG. 12 is a partial cross-sectional view of a sleeve member and
stator assembly according to one embodiment of the invention.

[0020]FIG. 13 is a perspective view of a portion of a stator assembly
according to one embodiment of the invention.

DETAILED DESCRIPTION

[0021] Before any embodiments of the invention are explained in detail, it
is to be understood that the invention is not limited in its application
to the details of construction and the arrangement of components set
forth in the following description or illustrated in the following
drawings. The invention is capable of other embodiments and of being
practiced or of being carried out in various ways. Also, it is to be
understood that the phraseology and terminology used herein is for the
purpose of description and should not be regarded as limiting. The use of
"including," "comprising," or "having" and variations thereof herein is
meant to encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise, the
terms "mounted," "connected," "supported," and "coupled" and variations
thereof are used broadly and encompass both direct and indirect
mountings, connections, supports, and couplings. Further, "connected" and
"coupled" are not restricted to physical or mechanical connections or
couplings.

[0022] The following discussion is presented to enable a person skilled in
the art to make and use embodiments of the invention. Various
modifications to the illustrated embodiments will be readily apparent to
those skilled in the art, and the generic principles herein can be
applied to other embodiments and applications without departing from
embodiments of the invention. Thus, embodiments of the invention are not
intended to be limited to embodiments shown, but are to be accorded the
widest scope consistent with the principles and features disclosed
herein. The following detailed description is to be read with reference
to the figures, in which like elements in different figures have like
reference numerals. The figures, which are not necessarily to scale,
depict selected embodiments and are not intended to limit the scope of
embodiments of the invention. Skilled artisans will recognize the
examples provided herein have many useful alternatives that fall within
the scope of embodiments of the invention.

[0023] FIGS. 1 and 2 illustrate an electric machine module 10 according to
one embodiment of the invention. The module 10 can include a housing 12,
which can define at least a portion of a machine cavity 14. In some
embodiments, an electric machine 16 can be housed within the machine
cavity 14 and at least partially enclosed by the housing 12. In some
embodiments, the housing 12 can comprise materials that can generally
include thermally conductive properties, such as, but not limited to
aluminum or other metals and materials capable of generally withstanding
operating temperatures of the electric machine 16. In some embodiments,
the housing 12 can be fabricated using different methods including
casting, molding, extruding, and other similar manufacturing methods. In
some embodiments, the electric machine 16 can be, without limitation, an
electric motor, such as a hybrid electric motor, an electric generator, a
vehicle alternator, and/or an induction belt-driven alternator-starter
(BAS).

[0024] In some embodiments, the electric machine 16 can include a rotor
assembly 18 and a stator assembly 20. In some embodiments, the stator
assembly 20 can circumscribe at least a portion of the rotor assembly 18.
In some embodiments, the rotor assembly 18 can include at least two
matingly-configured segments 22 coupled together. In some embodiments,
the segments 22 can comprise a Lundell-type configuration. In some
embodiments, the segments 22 can each include a plurality of claw poles
24 that are configured and arranged to matingly engage each other. For
example, in some embodiments, at least a portion of the claw poles 24 can
be configured and arranged so that during assembly, some of the claw
poles 24 can axially integrate (e.g., matingly engage and/or
interdigitate) so that a tip 26 of a claw pole 24 on one segment 22 is
substantially adjacent to a base 28 of a claw pole 24 on the other
segment 22, as shown in FIG. 3.

[0025] In some embodiments, during assembly of the module 10, the two
segments 22 can be coupled together. In some embodiments, the coupling of
the segments 22 can be at least partially performed by a ring member 30.
In some embodiments, the segments 22 can be coupled to at least a portion
of the ring member 30. For example, in some embodiments, the ring member
30 can comprise a first axial edge 32 and a second axial edge 34 and one
of the segments 22 can be coupled to the ring member 30 substantially
adjacent to the first axial edge 32 and the other segment 22 can be
coupled to the ring member 30 substantially adjacent to the second axial
edge 34. For example, in some embodiments, at least one of the segments
22 can be coupled to the ring member 30 using welding, brazing,
adhesives, conventional fasteners, etc. As a result, in some embodiments,
the segments 22 can be axially positioned with respect to the ring member
30 (i.e., the ring member 30 can be substantially centrally positioned
with respect to the segments 22). In some embodiments, the ring member 30
can comprise a substantially magnetically inert material, such as
stainless steel. Additionally, in some embodiments, the ring member 30
can comprise a plurality of apertures 36 positioned through portions of
the ring member 30 in a substantially circumferential orientation.

[0026] In some embodiments, the electric machine 16 can comprise a shaft
38. In some embodiments, at least one of the segments 22 can be
operatively coupled to the shaft 38. For example, in some embodiments, at
least one of the segments 22 can be rotatably coupled to the shaft 38 so
that rotation of the shaft 38 causes rotation of the rotor assembly 18
(e.g., the rotor assembly 18 and the shaft 38 can substantially
synchronously rotate). Additionally, in some embodiments, the shaft 38
can be coupled to a pulley 40. In some embodiments, the pulley 40 can be
coupled to an energy generation apparatus (not shown) to provide a force
to rotate the pulley 40, which can be translated to rotation of the shaft
38 and the rotor assembly 18. By way of example only, in some
embodiments, the pulley 40 can be coupled to an engine via a belt (not
shown) so that belt movement can rotate the pulley 40.

[0027] In some embodiments, the rotor assembly 18 can substantially
circumscribe at least a portion of a support member 42 that can include a
field coil 44. In some embodiments, the support member 42 can be coupled
to a portion of the housing 12 so that during operation of the module 10,
the support member 42 can remain substantially stationary. Moreover, in
some embodiments, the support member 42 can be coupled to the housing 12
so that it axially extends into the machine cavity 14 and can be received
by at least a portion of the rotor assembly 18. In some embodiments, the
support member 42 can be coupled to the housing 12 using conventional
fasteners 46, and in other embodiments, the support member 42 can be
coupled to the housing 12 in other manners or the support member 42 can
be substantially integral with the housing 12. Additionally, in some
embodiments, the support member 42 can comprise a generally annular
configuration, as shown in FIG. 4. In other embodiments, the support
member 42 can comprise other configurations (e.g., square, rectangular,
regular or irregular polygonal, etc.) that can be received within at
least a portion of the rotor assembly 18.

[0028] In some embodiments, the field coil 44 can circumscribe at least a
portion of the support member 42. In some embodiments, the field coil 44
can comprise at least one wire wound around at least a portion of an
outer diameter of the support member 42. For example, in some
embodiments, the field coil 44 can be wound around the support member 42
multiple times so that the field coil 44 comprises multiple layers in a
generally radial orientation. In some embodiments, the field coil 44 can
comprise a copper-containing material.

[0029] In some embodiments, the module 10 can comprise a brushless
configuration. In some embodiments, the field coil 44 can be electrically
connected to a current source (not shown). As a result, in some
embodiments, a current can circulate from the current source to the field
coil 44 for use in operations of the electric machine 20. In some
embodiments, as result of the substantially stationary support member 42
and field coil 44, the module 10 can be brushless (e.g., no brushes
and/or slip rings are necessary for circulating current through the field
coil 44). Relative to some conventional electric machines, the brushless
configuration can offer some benefits. By way of example only, the
brushes of some conventional electric machines can experience heavy wear
during machine operations, which can lead to frequent maintenance. In
some embodiments of the invention, by including a stationary support
member 42 and field coil 44 in a brushless configuration, the requirement
for brush repair can be at least partially obviated. Additionally, as
described in further detail below, the brushless configuration can at
least partially enable improved electric machine 16 cooling, which can
result in greater electric machine output (e.g. amperes).

[0030] As shown in FIGS. 5 and 6, in some embodiments, the stator assembly
20 can comprise a stator core 48 and a stator winding 50 at least
partially disposed within a portion of the stator core 48. For example,
in some embodiments, the stator core 48 can comprise a plurality of
laminations 52. Referring to FIG. 7, in some embodiments, the laminations
52 can comprise a plurality of substantially radially-oriented teeth 54.
In some embodiments, as shown in FIGS. 5 and 6, when at least a portion
of the plurality of laminations 52 are substantially assembled, the teeth
54 can substantially align to define a plurality of slots 56 that are
configured and arranged to support at least a portion of the stator
winding 50. As shown in FIGS. 5 and 6, in some embodiments, the
laminations 52 can include multiple teeth 54, and, as a result, the
stator core 48 can include multiple slots 56.

[0031] As shown in FIG. 7, in some embodiments, at least a portion of the
laminations 52 can comprise a yoke 58. In some embodiments, the
laminations 52 can be formed so that the yoke 58 is substantially
radially outward from the teeth 54. Moreover, in some embodiments, at
least some of the laminations 52 can comprise a plurality of scallops 60.
In some embodiments, an outer diameter 62 of some of the laminations 52
can comprise the scallops 60. For example, in some embodiments, the
scallops 60 can be positioned around at least a portion of a
circumference of the laminations 52, as shown in FIG. 7. In some
embodiments, the scallops 60 can all be substantially uniform in size,
however, in other embodiments, the scallops 60 can vary in size (e.g.,
some scallops 60 can include a greater or lesser perimeter relative to
other scallops 60). Additionally, although depicted in a generally
semi-circular configuration, in some embodiments, the scallops 60 can
comprise other shapes such as square, rectangular, regular or irregular
polygonal, etc.

[0032] Additionally, in some embodiments, the outer diameter 62 can
comprise at least one recess 61. In some embodiments, the laminations 52
can comprise a plurality of recesses 61. In some embodiments, the
recesses 61 can be positioned in different locations around portions of
the outer diameter 62. For example, a generally lower portion of the
lamination 52 can comprise at least some recesses 61 to enable coolant
flow, as detailed below. Moreover, in some embodiments, the generally
upper portion of the lamination 52 can comprise at least one recess 61 to
enable air movement within the machine cavity 14 to at least partially
prevent formation of a vacuum during coolant drainage, as detailed below.
Moreover, in some embodiments, the entire outer diameter 62 of each
lamination 52 can comprise the scallops 60, although, in some
embodiments, the recess 61 portion of the outer diameter 62 can
substantially lack the scallops 60.

[0033] In some embodiments, the scallops 60 can at least partially improve
electric machine 16 operations. For example, in some embodiments, the
scallops 60 can at least partially lead to an increased surface area of
the outer diameter of the stator core 48 when laminations 52 are coupled
together. As a result, in some embodiments, at least a portion of the
heat energy produced by the stator assembly 20 can be more easily
transferred (e.g., conducted) to the housing 12 or transferred (e.g.,
convected) to the air in the machine cavity 14.

[0034] In some embodiments, the laminations 52 can comprise different
compositions. In some embodiments, the laminations 52 can comprise a
material that can at least partially minimize stator core losses. In some
embodiments, at least a portion of the laminations 54 can comprise a
silicon-steel composition. By way of example only, in some embodiments,
the laminations 52 can comprise electrical grade steel, such as M36, M47,
or another grade of steel. Compared to some conventional laminations, the
composition used to create the laminations 52 can offer advantages. For
example, some conventional laminations can comprise a generally low-grade
carbon-containing composition, which can be slightly more cost effective,
but, compared to some embodiments of the invention, can be at least
partially less efficient and can lead to poorer performance by the
electric machine 16. Additionally, in some embodiments, by including
laminations 52 comprising the silicon-steel composition, stator core
losses such as hysteresis and eddy currents can be minimized, which can
at least partially correlate with increased efficiency and a generally
greater output compared to some conventional electric machines.

[0035] In some embodiments, the stator winding 50 can comprise a plurality
of conductors 64. In some embodiments, the conductors 64 can comprise a
substantially segmented configuration (e.g., a hairpin configuration), as
shown in FIG. 8. For example, in some embodiments, at least a portion of
the conductors 64 can include a turn portion 66 and at least two leg
portions 68. In some embodiments, the turn portion 66 can be disposed
between the two leg portions 68 to substantially connect the two leg
portions 68. In some embodiments, the leg portions 68 can be
substantially parallel. Moreover, in some embodiments, the turn portion
66 can comprise a substantially "u-shaped" configuration, although, in
some embodiments, the turn portion 66 can comprise a v-shape, a wave
shape, a curved shape, and other shapes. Additionally, in some
embodiments, as shown in FIG. 8, at least a portion of the conductors 64
can comprise a substantially rectangular cross section. In some
embodiments, at least a portion of the conductors 64 can comprise other
cross-sectional shapes, such as substantially circular, square,
hemispherical, regular or irregular polygonal, etc.

[0036] Furthermore, in some embodiments, the cross-section of the
conductors 64 can be substantially similar to the cross-section of the
slots 56. For example, in some embodiments, the conductors 64 and the
slots 56 can comprise a substantially rectangular cross section. As a
result of the substantially similar cross sections, a slot fill
percentage (e.g., a ratio of the cross-sectional area of the conductors
to the cross-sectional area of the slots) can be at least partially
increased. Accordingly, some embodiments of the invention can exhibit
improved efficiency, increased output, and decreased conductor resistance
relative to some conventional electric machines because those machines
can include conductors and slots with substantially different
cross-sections (e.g., conductors with a substantially circular
cross-section in a slot with a substantially rectangular cross section),
which can reduce slot fill percentage and lead to a decrease in
performance.

[0037] In some embodiments, as shown in FIG. 5, at least a portion of the
conductors 64 can be positioned substantially within the slots 56. For
example, in some embodiments, the stator core 48 can be configured so
that the plurality of slots 56 are substantially axially arranged. In
some embodiments, the leg portions 68 can be inserted into the slots 56
so that at least some of the leg portions 68 can axially extend through
the stator core 48. In some embodiments, the leg portions 68 can be
inserted into neighboring slots 56. For example, in some embodiments, the
leg portions 68 of a conductor 64 can be disposed in slots that are
distanced approximately one magnetic-pole pitch apart (e.g., six slots,
eight slots, etc.).

[0038] Moreover, in some embodiments, the stator winding 50 can comprise a
distributed winding configuration. As discussed in further detail below,
the stator winding 50 can comprise a plurality of phases. For example, in
some embodiments, at least some of the slots 56 can include multiple
phases. Moreover, in some embodiments, because the leg portions 68 of
conductors are inserted into different slots 56 and each slot 56 can
comprise multiple slots, operations of the electric machine 16 can be at
least partially improved. For example, relative to some conventional
electric machines that can include a concentrated winding, some of the
magnetic noise produced as a result of electric machine operations can be
at least partially reduced. Furthermore, torque ripple can also be
reduced in some embodiments including a distributed winding configuration
relative to a concentrated winding configuration. As a result of the
reduction of some of the drawbacks associated with concentrated windings,
some embodiments of the invention can produce an increased amount of
output.

[0039] In some embodiments, a plurality of conductors 64 can be disposed
in the stator core 48 so that at least some of the turn portions 66 of
the conductors 64 axially extend from the stator core 48 at an insertion
end 70 of the stator core 48 and at least some of the leg portions 68
axially extend from the stator core 48 at a weld end 72 of the stator
core 48. In some embodiments, the conductors 64 can be fabricated from a
substantially linear conductor 64 that can be configured and arranged to
a shape substantially similar to the conductor in FIG. 5. For example, in
some embodiments, a machine (not shown) can apply a force (e.g., bend,
push, pull, other otherwise actuate) to at least a portion of a conductor
64 to substantially form the turn portion 66 and the two leg portions 68
of a single conductor 64.

[0040] In some embodiments, at least some of the leg portions 68 can
comprise multiple regions. In some embodiments, the leg portions 68 can
comprise in-slot portions 74, angled portions 76, and connection portions
78. In some embodiments, as previously mentioned, the leg portions 68 can
be disposed in the slots 56 and can axially extend from the insertion end
70 to the weld end 72. In some embodiments, after insertion, at least a
portion of the leg portions 68 positioned within the slots 56 can
comprise the in-slot portions 74.

[0041] In some embodiments, at least some of a regions of the leg portions
68 extending from stator core 48 at the weld end 72 can comprise the
angled portions 76 and the connection portions 78. In some embodiments,
after inserting the conductors 64 into the stator core 48, the leg
portions 68 extending from the stator core 48 at the weld end 72 can
undergo a twisting process (not shown) which can lead to the creation of
the angled portions 76 and the connection portions 78. For example, in
some embodiments, the twisting process can give rise to the angled
portions 76 at a more axially inward position and the connection portions
78 at a more axially outward position. In some embodiments, after the
twisting process, the connection portions 78 of at least a portion of the
conductors 64 can be immediately adjacent to connection portions 78 of
other conductors 64. As a result, the connection portions 78 can be
coupled together to form one or more stator windings 50. In some
embodiments, the connection portions 78 can be coupled via welding,
brazing, soldering, melting, adhesives, or other coupling methods.

[0042] In some embodiments, the stator winding 50 can comprise a
multi-phase stator winding. For example, in some embodiments, the stator
winding 50 can comprise a three-phase stator winding 50 and each phase
can be electrically coupled to a rectifier assembly 80 via terminals 82
and leads (not shown). In some embodiments, each phase of the stator
winding 50 can be electrically coupled to a terminal 82. For example, as
a result, during electric machine operations, when current flows through
the field coil 44 and the rotor assembly 18 is rotating, a voltage can be
generated in each of the phases of the stator winding 50 due to the
magnetic field produced by the rotor assembly 18 and field coil 44. The
voltage generated in each of the phases can lead an alternating current
to circulate through the conductors 64 and to the rectifier assembly 80
via the terminals 82 and leads. In some embodiments, the rectifier
assembly 80 can convert the alternating current produced to direct
current for recharging any batteries (not shown) or other loads
electrically connected to the module 10.

[0043] In some embodiments, the module 10 can comprise a plurality of
machine cavities 14. In some embodiments, the stator assembly 20 and the
rotor assembly 18 can be positioned within a first machine cavity 14a and
the rectifier assembly 80 can be positioned within a second machine
cavity 14b. For example, in some embodiments, the housing 12 can comprise
a sleeve member 84 coupled to a first end cap 86 and a second end cap 88.
In some embodiments, the sleeve member 84 can be coupled to the end caps
86, 88 via conventional fasteners 89 (e.g., screws, bolts, etc.) or via
any other coupling techniques. In some embodiments, the sleeve member 84
can substantially circumscribe at least a portion of the stator assembly
20 and the end caps 86, 88 can be coupled to opposing axial sides of the
sleeve member 84.

[0044] In some embodiments, at least one of the end caps 86, 88 can be
configured and arranged to receive the rectifier assembly 80. For
example, as shown in FIGS. 9A and 9B, in some embodiments, the rectifier
assembly 80 can be positioned within a recess 90 at least partially
defined by one of the end caps 86, 88. In some embodiments, electrical
connections can extend through walls of one of the end caps 86, 88 to
electrically couple the rectifier assembly 80 with the stator assembly 20
and current-requiring loads outside of the module 10. Additionally, in
some embodiments, a third end cap 92 can be coupled to the housing 12 to
substantially seal the recess 90 to provide at least physical insulation
for the rectifier assembly 80 and to at least partially define the second
machine cavity 14b.

[0045] In some embodiments, at least one of the end caps 86, 88 opposite
the rectifier assembly 80 can comprise an alternative configuration. For
example, in some embodiments, the first end cap 86 can comprise the
rectifier assembly 80 and can generally include a configuration
substantially similar to some previously mentioned embodiments, and the
second end cap 88 can comprise an different configuration or vice versa.
Although the description details the second end cap 88 comprising a
configuration different from the first end cap 86, either end cap 86, 88
can comprise either configuration. Moreover, in some embodiments, the end
caps 86, 88 can comprise a substantially similar configuration (not
shown). In some embodiments, the second end cap 88 can be configured to
receive and support at least a portion of the shaft 38. For example, as
shown in FIGS. 9A and 9B, the shaft 38 can axially extend through at
least a portion of the second end cap 88 and can be at least partially
supported by a bearing assembly 91. Moreover, as discussed in further
detail below, in some embodiments, the second end cap 88 can comprise at
least a plurality of passages 93 configured and arranged to guide at
least a portion of a coolant through regions of the second end cap 88 and
other portions of the module 10.

[0046] In some embodiments, the module 10 can comprise a cooling system
94. In some embodiments, the cooling system 94 can comprise an inlet 96
positioned through a portion of the housing 12. In some embodiments, the
cooling system 94 can comprise a plurality of inlets 96. For example, in
some embodiments, the inlet 96 can be positioned substantially adjacent
to the rectifier assembly 80 and can be in fluid communication with a
coolant source (not shown). Also, in some embodiments, the inlet 96 can
be in fluid communication with at least one of the machine cavities 14a,
14b. For example, in some embodiments, the inlet 96 can fluidly couple
the coolant source to the second machine cavity 14b so that a coolant can
enter the second machine cavity 14b, which can at least partially enhance
electric machine cooling.

[0047] In some embodiments, the coolant can comprise transmission fluid,
ethylene glycol, an ethylene glycol/water mixture, water, oil, motor oil,
a mist, a gas, or another substance capable of receiving heat energy
produced by the electric machine module 10. Also, in some embodiments,
the coolant source can at least partially pressurize the coolant prior to
or as it is being dispersed into the second machine cavity 14b via the
inlet 96.

[0048] In some embodiments, the coolant can at least partially accumulate
within the second machine cavity 14b. For example, in some embodiments, a
volume of coolant can enter the second machine cavity 14b, and, because
the second machine cavity 14b is substantially sealed, as previously
mentioned, at least a portion of the coolant can remain within the second
machine cavity 14b, as shown in FIG. 9B. As a result, in some
embodiments, the coolant can receive at least a portion of the heat
energy produced by the rectifier assembly 80, which can lead to at least
partial cooling of the electric machine module 10.

[0049] In some embodiments, the cooling system 94 can comprise a first
channel 98. In some embodiments, the cooling system 94 can comprise a
plurality of first channels 98. In some embodiments, the first channel 98
can be at least partially positioned within the support member 42. For
example, in some embodiments, the first channel 98 can be oriented in a
substantially axial direction (e.g., substantially parallel to a central
axis of rotation of the electric machine 16). In some embodiments, the
support member 42 can be formed (e.g., cast, molded, etc.) so that the
first channel 98 is substantially integral with the support member 42.
Additionally, in other embodiments, the first channel 98 can be machined
into the support member 42 at a point after support member 42
manufacture. In some embodiments, the first channel 98 can comprise an
open end 100 and a substantially sealed end 102 as shown on F16.2. As a
result, a fluid can enter the first channel 98 at the open end 100 and
can flow toward the sealed end 102, but cannot exit the first channel 98
at the sealed end 102. However, in some embodiments, the first channel 98
can comprise two open ends 100 so that the fluid can readily flow through
the first channel 98. Moreover, in some embodiments, the first channel 98
can comprise a substantially cylindrical shape, although in other
embodiments, the first channel 98 can comprise other shapes (e.g.,
square, rectangular, regular or irregular polygonal, etc.).

[0050] In some embodiments, first channel 98 can be in fluid communication
with at least one of the machine cavities 14a, 14b. For example, in some
embodiments, a wall 104 of the housing 12, at least a portion of which is
positioned between the machine cavities 14a, 14b, can be configured and
arranged so that the first channel 98 can be in fluid communication with
the second machine cavity 14b. In some embodiments, the support member 42
can be positioned so that the open end 100 of the first channel 98 is
immediately adjacent to the wall 104. As a result, in some embodiments,
at least a portion of the coolant that enters the second machine cavity
14b can enter the first channel 98 via the open end 100. For example, in
some embodiments, the wall 104 can comprise at least one aperture 101
that can be configured and arranged to fluidly connect the second machine
cavity 14b and the open end 100 of the first channel 98 so that at least
a portion of the coolant can enter the first channel 98. In some
embodiments, more than one aperture 101 can be disposed through the wall
104 to fluidly couple the second machine cavity 14b and the first channel
98.

[0051] Additionally, in some embodiments, the connection of the first
channel 98 and the second machine cavity 14b can be configured and
arranged to enhance cooling of the module 10 components in the second
machine cavity 14b. In some embodiments, the aperture 101 through the
wall 104 can be positioned a pre-determined distance from a bottom
portion of the second machine cavity 14b. For example, in some
embodiments, the aperture 101 can be positioned a great enough distance
from the bottom portion of the second machine cavity 14b so that the
coolant can accumulate within a significant portion of the second machine
cavity 14b (e.g., the coolant can substantially flood the second machine
cavity 14b), which can result in at least partially enhanced cooling of
the module 10.

[0052] As shown in FIG. 2, in some embodiments, the cooling system 94 can
comprise at least one second channel 106. For example, in some
embodiments, the support member 42 can comprise the second channel 106,
although in some embodiments, the support member 42 can comprise more
than one second channel 106, as shown in FIG. 2. In some embodiments, the
second channel 106 can be substantially radially oriented through at
least a portion of the support member 42. In some embodiments, similar to
the first channel 98, the second channel 106 can be formed either
substantially at the same time as formation of the support member 42
(e.g., casting, molding, etc.) or can be later machined into the support
member 42.

[0053] Additionally, in some embodiments comprising multiple second
channels 106, in some embodiments, one of the second channels 106 can be
positioned substantially adjacent to the open end 100 and another second
channel 106 can be positioned substantially adjacent to the closed end
102. In some embodiments, as described in further detail below, at least
a portion of the second channels 106 can comprise different dimensions
(e.g., diameter, circumference, perimeter, etc.). Moreover, in some
embodiments, at least some of the second channels 106 can comprise a
substantially cylindrical shape, although in other embodiments, the
second channels 106 can comprise other shapes (e.g., square, rectangular,
regular or irregular polygonal, etc.).

[0054] In some embodiments, at least a portion of the second channels 106
can fluidly connect the first channel 98 with the first machine cavity
14a. For example, in some embodiments, the second channels 106 can be
configured and arranged to direct at least a portion of the coolant that
enters the first channel 98 into the machine cavity 14a so that at least
some of the coolant can contact portions of the module 10 to aid in
cooling.

[0055] In some embodiments, because the support member 42 remains
substantially stationary during operation of the module 10, the second
channels 106 can be arranged to at least partially enhance coolant
dispersal. For example, in some embodiments, at least a portion of the
second channels 106 can extend from the first channel 98 in a radially
downward direction and some of the second channels 106 can extend from
the first channel 98 in a radially upward direction. As a result,
although the support member 42 does not rotate to aid in dispersing
coolant to the first machine cavity 14a, by including second channels 106
arranged to disperse coolant in a plurality of different radial
directions, the coolant can be more evenly dispersed throughout the first
machine cavity 14a relative to embodiments where coolant is dispersed in
fewer directions.

[0056] Moreover, in some embodiments, as previously mentioned, at least a
portion of the second channels 106 can comprise different configurations.
In some embodiments, the different configurations of the second channels
106 can at least partially aid in directing coolant flow. As previously
mentioned, the second channels 106 can comprise a variety of different
configurations, and, although some later references may be to
configurations that indicate substantially cylindrical second channels
106 (e.g., circumference, diameter, etc.), those references are in no way
intended to limit the configuration of the channels 106 to a
substantially cylindrical configuration. In some embodiments, at least
one of the second channels 106 can comprise a greater diameter than
another second channel 106. For example, in some embodiments, the second
channel 106 that is positioned substantially adjacent to the open end 100
of the first channel 98 can comprise a lesser diameter compared to the
second channel 106 substantially adjacent to the closed end 102. In some
embodiments, coolant flow through the second channel 106 substantially
adjacent to the open end 100 can be at least partially restricted. As a
result, in some embodiments, at least a portion of the coolant entering
the first channel 98 will be directed toward the second channel 106
adjacent to the closed end 102, which can lead to more even cooling
(e.g., coolant can exit the first channel 98 through multiple second
channels 106) of the module 10. Furthermore, in some embodiments, the
pressure created by the coolant source can at least partially urge,
direct, and/or drive at least a portion of the coolant through the
cooling system 94.

[0057] In some embodiments, the rotor assembly 18 can aid in dispersing at
least a portion of the coolant throughout the first machine cavity 14a,
as reflected by some of the arrows in FIG. 9B. In some embodiments, at
least a portion of the second channels 106 can comprise coolant outlets
108 positioned at radially outermost regions of the second channels 106.
Moreover, in some embodiments, at least a portion of the coolant outlets
108 can be positioned substantially immediately radially inward from
portions of the rotor assembly 18. Accordingly, in some embodiments, if
the rotor assembly 18 is moving during module 10 operations and coolant
exits the outlets 108, the movement of the rotor assembly 18 can lead to
at least a portion of the cooling being dispersed throughout the first
machine cavity 14a (e.g., via "splashing" due to rotor assembly 18
movement), as reflected by some of the arrows in FIG. 9B. In some
embodiments, portions of the coolant can contact various module 10
elements including, but not limited to the housing 12, the stator
assembly 20, the stator winding 50, the shaft 38, and other elements,
which can lead to at least partial cooling and lubrication of module 10
components. Moreover, in some embodiments comprising at least some
scallops 60, cooling can be at least partially enhanced. For example, as
previously mentioned, the scallops 60 can at least partially increase
surface area on the outer diameter of the stator core 48. As a result of
the increase surface area, more coolant can contact at least a portion of
the stator core 48, which can lead to at least partially enhanced
cooling.

[0058] In some embodiments, the cooling system 94 can comprise at least
one third channel 110. In some embodiments, the inlet 96 can be
configured and arranged to divide at least a portion of the coolant from
the coolant source into at least two different directions. In some
embodiments, the inlet 96 can comprise a "tee" configuration so that at
least a portion of the coolant can enter the second machine cavity 14b,
as previously mentioned, and another portion of the coolant can be
directed to the third channel 110, as shown in FIGS. 10A and 10B.

[0059] For example, as shown in FIG. 10B, in some embodiments, the inlet
96 can comprise a inlet aperture 96a and at least two outlet apertures
96b, 96c. In some embodiments, at least one of the outlet apertures 96b,
96c can fluidly couple the inlet aperture 96a and the second machine
cavity 14b. In some embodiments, at least one of the outlet apertures
96b, 96c can fluidly couple the inlet aperture 96a and the third channel
110. As a result, in some embodiments, as coolant enters the inlet 96 via
the inlet aperture 96a, at least a portion of the coolant can enter the
third channel 110 via at least one of the outlet apertures 96b, 96c and
another portion of the coolant can enter the second machine cavity 14b
via another of the outlet apertures 96b, 96c.

[0060] In some embodiments, at least a portion of the third channel 110
can be substantially exterior to the housing 12. For example, as shown in
FIG. 9A, in some embodiments, at least a portion of the third channel 110
can be coupled to an exterior portion of the housing 12 so that a portion
of the coolant can be transported to a portion of the housing 12 that is
substantially axially opposite to the second machine cavity 14b (e.g.,
the second end cap 88). In some embodiments, the third channel 110 can be
in fluid communication with a second inlet 112, which can be in fluid
communication with the first machine cavity 14a and the passages 93
defined in the second end cap 88. For example, in some embodiments, at
least a portion of the coolant can flow through the passages 93 and can
contact portions of the end cap 88, the shaft 38, the bearing assembly
91, and other portions of the module 10. Moreover, as shown in FIG. 9B,
in some embodiments at least a portion of the passages 93 can fluidly
connect the second inlet 112 and the first machine cavity 14a so that at
least a portion of the coolant that enters the passages 93 via the second
inlet 112 can eventually enter the first machine cavity 14a. As a result,
in some embodiments, coolant can be more evenly distributed to the
machine cavities 14a, 14b and various elements of the module 10.

[0061] In some embodiments, after entering the first machine cavity 14a,
at least a portion of the coolant can contact various elements of the
module 10 and can then drain from the module 10. In some embodiments, the
housing 12 can comprise at least one drain aperture 114 that can be in
fluid communication with at least one of the first machine cavity 14a and
the second machine cavity 14b. For example, in some embodiments, the
drain aperture 114 can be positioned in a substantially lower portion of
the housing 12, so that, after entering the first machine cavity 14a, at
least a portion of the coolant can drain generally downward (e.g., via
gravity and/or pressure) and can exit the machine cavity 14a so as not to
accumulate in the first machine cavity 14a. In some embodiments, the
drain aperture 114 can be in fluid communication with a heat exchange
element (e.g., a radiator, a heat exchanger, etc.) (not shown) so at
least a portion of the coolant can flow from the drain aperture 114 to
the heat exchange element where at least a portion of the heat energy
received by the coolant can be removed. In some embodiments, the drain
aperture 114 can comprise threading, as shown in FIG. 11. In some
embodiments, the threading can at least partially enable coupling between
the drain aperture 114 and the heat exchange element. In other
embodiments, the drain aperture 114 and the heat exchange element can be
coupled in other manners (e.g., interference fit, adhesives, conventional
fasteners, etc.) In some embodiments, the heat exchange element can be
fluidly connected to the coolant source or can comprise the coolant
source so that the coolant can be recycled for further use in module 10
cooling.

[0062] In some embodiments, the module 10 can comprise enhanced drainage
capability. In some embodiments, in order to at least partially enhance
cooling of the module 10, a greater volume of coolant can be circulated
through portions of the module 10, as previously mentioned. In some
embodiments, more heat energy can be conducted away from the module 10,
which can at least partially enhance module 10 operations. As a result,
in some embodiments, the module 10 can comprise greater drainage
capability to account for an increased volume of coolant. For example, if
too great a volume of coolant accumulates within portions of the first
machine cavity 14a, an air gap 116 defined between the rotor assembly 18
and the stator assembly 20 can become at least partially flooded, which
can negatively impact machine 16 operations. For example, by at least
partially flooding the first machine cavity 14a, excess heat can
accumulate within the module because of coolant shear associated with an
at least partially flooded air gap 116.

[0063] In some embodiments, the module 10 can comprise at least one drain
guide 118. In some embodiments, the housing 12 can comprise the drain
guide 118 positioned substantially adjacent to the drain aperture 114.
For example, in some embodiments, the sleeve member 84 can comprise an
inner wall 120 that at least partially defines a portion of the first
machine cavity 14a and the inner wall 120 can comprise at least a portion
of the drain guide 118, as shown in FIG. 11. In some embodiments, the
drain guide 118 can be positioned after manufacture of the sleeve member
84 (e.g., the drain guide 118 can be machined into the sleeve member 84).
In some embodiments, the sleeve member 84 can be formed so that the drain
guide 118 is substantially integral at the time of sleeve member 84
manufacture (e.g., the sleeve member 84 can be cast, molded, or otherwise
formed with the drain guide 118 being formed at substantially the same
time). Moreover, in some embodiment, the sleeve member 84 can comprise
multiple drain guides 118 (e.g., three drain guides) and at least a
portion of the guides 118 can be formed after sleeve member 84
manufacture and at least a portion of the guides 118 can be formed at
substantially the same time as sleeve member 84 manufacture. Although, in
some embodiments, the drain guides 118 can be manufactured at
substantially the same time and in substantially the same manner.

[0064] In some embodiments, the drain guides 118 can comprise multiple
configurations. For example, as shown in FIG. 11, in some embodiments, at
least a portion of the drain guides 118 can comprise a substantially
semi-circular and/or curved configuration (e.g., a substantially
"u-shaped" configuration). In some embodiments, at least a portion of the
drain guides 118 can comprise an angled configuration (e.g., a
substantially "v-shaped" configuration). In some embodiments, at least a
portion of the drain guides 118 can comprise other shapes and
configurations that can at least partially enable a portion of coolant to
flow toward the drain aperture 114 (e.g., a structure extending radially
inward from the inner wall 120 or other recessed structures).

[0065] In some embodiments, at least a portion of the drain guides 118 can
be configured and arranged to guide at least a portion of the coolant
toward the drain aperture 114. As shown in FIGS. 11 and 12, in some
embodiments, the drain aperture 114 can be in fluid communication with at
least one of the drain guides 118. For example, as shown in FIGS. 11 and
12, in some embodiments, at least one of the drain guides 118 can be
positioned on the sleeve member 84 so that at least a portion of the
drain aperture 114 substantially overlaps with a portion of at least one
of the drain guides 118. For example, in some embodiments, the drain
aperture 114 can be disposed through a portion of the sleeve member 84 so
at least a portion of the drain apertures 114 is substantially contiguous
with at least one of the guides 118 or vice versa.

[0066] In some embodiments, the stator assembly 20 can be coupled to the
sleeve member 84 to at least partially enable drainage of coolant through
the drain aperture 114. For example, in some embodiments, the sleeve
member 84 can be coupled to the sleeve member 84 so that at least a
portion of the recesses 61 are substantially adjacent to the drain
aperture 114 and/or at least a portion of the drain guides 118. As shown
in FIG. 12, in some embodiments, at least one of the recesses 61 can be
substantially radially inward from at least one of the drain guides 118
and/or the drain aperture 114 so that coolant can readily flow in a space
defined between the outer diameter of the stator assembly 20 and the
sleeve member 84 (e.g., portions of the drain guides 118 and/or the inner
wall 120).

[0067] Moreover, in some embodiments, as previously mentioned, the sleeve
member 84 can comprise more than one drain guide 118 and the stator
assembly 20 can comprise more than one recess 61. Accordingly, in some
embodiments, the stator assembly 20 can be coupled to the sleeve member
84 so that at least a portion of the recesses 61 substantially align with
at least a portion of the drain guides 118. As a result, in some
embodiments, at least a portion of the coolant can flow from the coolant
system 94 and more readily flow through the spaces defined between the
drain guides 118 and the recesses 61 relative to some embodiments not
including the drain guides 118 because of the increased size of the space
between the stator assembly 20 and the sleeve member 84.

[0068] Although the following example demonstrates the potential impact of
the drain guides 118 on draining coolant from the module 10, these
results are included for exemplary purposes only and in no way limit the
scope of this disclosure. By way of example only, in some embodiments,
greater numbers of drain guides 118 can at least partially lead to
enhanced coolant drainage. For example, when comparing comparable modules
10 that include one drain guide 118 versus three drain guides 118, the
module 10 including three drain guides 118 is able to drain coolant at a
greater rate, and as a result, included lower levels of coolant in the
machine cavity 14a. For example, when circulating approximately 1.3
gallons per minute of coolant through the module 10, modules 10 including
three drain guides 118 exhibited an approximately 50% lesser level of
coolant within the machine cavity 14a relative to modules 10 including a
single drain guides 118 when the rotor assembly 18 was rotating at
approximately 1600 RPM. Additionally, at a greater flow rate of coolant
(e.g., 1.4 gallons per minute), modules 10 including three drain guides
118 still exhibit an approximately 50% lesser level of coolant relative
to modules 10 including one drain guide 118. Moreover, at higher rotor
assembly 18 velocities (e.g., 6500 RPM), regardless of coolant flow rate
(e.g., 1.3 gallons per minute or 1.4 gallons per minute), modules 10
including three drain guides 118 continue to exhibit an approximately 25%
lesser level of coolant relative to modules 10 including a single drain
guide 118. As a result, the greater the number of drain guides 118, the
greater capability the module 10 can comprise for draining coolant
through the module 10.

[0069] In some embodiments, the stator core 48 be configured and arranged
to at least partially enhance coolant drainage. In some embodiments, an
outer diameter of a region 122 of the stator core 48 substantially
adjacent to the drainage aperture 114 can be at least partially reduced
so that the outer diameter of the region 122 is substantially similar to
the outer diameter of portions of the stator core 48 comprising the
recesses 61. For example, in some embodiments, the region 122 can further
increase the area defined between the stator core 48 and the inner wall
120 in a position substantially adjacent to the drain aperture 114 so
that coolant can more easily flow to the drain aperture 114 relative to
embodiments without the region 122 with a reduced outer diameter. In some
embodiments, the region 122 can be formed by machining after assembly of
the core 48, although in other embodiments, the core 48 can comprise
laminations 52 configured and arranged to define the region 122.

[0070] In some embodiments, at least some of the cooling configurations
can be more efficient than cooling configurations found in some
conventional electric machines. Some conventional machines can be cooled
by air flow. Because many electric machines, such as alternators,
generators, and electric motors can be installed in portions of some
vehicles (e.g., an engine of a bus, car, or other method of
transportation) and can be substantially air-cooled, at least some
conventional electric machines can operate at less than optimal levels.
For example, during operation of an engine, the ambient temperature
around an electric machine can be around 125 degrees Celsius, which means
that to cool the machine, 125 degree air will be drawn into the housing
for cooling. For some conventional electric machines, this 125 degree air
can offer minimal cooling during operations, which can negatively impact
machine performance and output. In some embodiments of the invention, by
circulating a coolant through the module 10, the operating temperature of
the electric machine 16 can be at least partially reduced because the
coolant can produce convection coefficients on the various surfaces that
the coolant contacts that can be at least an order of magnitude greater
than some conventional, air-cooled electric machines. Moreover, in some
embodiments, because the temperature of the coolant can be at least
partially controlled by a heat exchange element, as previously mentioned,
the coolant can enter the module 10 at a lesser temperature relative air
from an operating engine (e.g., 110 degrees Celsius v. 125 degrees
Celsius), which can improve cooling.

[0071] It will be appreciated by those skilled in the art that while the
invention has been described above in connection with particular
embodiments and examples, the invention is not necessarily so limited,
and that numerous other embodiments, examples, uses, modifications and
departures from the embodiments, examples and uses are intended to be
encompassed by the claims attached hereto. The entire disclosure of each
patent and publication cited herein is incorporated by reference, as if
each such patent or publication were individually incorporated by
reference herein. Various features and advantages of the invention are
set forth in the following claims.